[Randy Ferguson]

I'm in the process of building an aluminum front end for a '63 SD Tempest and thought I would share the process with you fine folks.

The first step is to capture as much information from the original part as possible. In this case, a donor steel front end is being used to create bucks to fit the new panels to. The inner structure is first removed, then the interior side of the panels are cleaned and waxed. (The wax acts as a release agent.)

A grid of 1/4" rods are then laid out at about 6-8" intervals. After the rods are welded, gussets added, etc., fiberglass reinforced body filler is used around the perimeter in areas where the buck will double as a hammerform. The rest of the rods are covered with regular cheap body filler, as those are used only as a guide to make sure the panels are shaped properly.

About 4" from the upper fender mounting flange, there is a bolt flange incorporated in the design of the buck, making it modular to allow the buck to be removed from the original panel as well as removing new parts from the buck as they are completed. Without being able to break down the buck, it would be locked in place due to flanges, undercuts, etc.






Since there is quite a bit of shape in the lower half of these fenders, I chose to make quick, inexpensive dies to stamp those areas. Those were made from laying up 6-8 layers of fiberglass mat and resin on the inside of the fender, then body filler was thinned with fiberglass resin to get a consistency that is pourable and self leveling. The finished die ends up being 2-3" thick and quite durable, believe it or not.





With all that boring stuff out of the way, it's time to start shaping panels.

This is after a couple hits in the stamping press. I'm very new to stamping, so there is still a lot to learn, but that's part of the fun.

The aluminum blank is laid on top of the dies, then 3/4" rubber pads are added to the top of the aluminum blank as needed between cycles in the press to get the aluminum to conform to the die.

This panel is obviously not finished at this point, but it is promising to be a viable approach. I ended up making a small section of an upper die to get the rest of the definition where the bumper mounts. It wasn't getting a deep enough draw with the rubber pads. Part of that is no doubt due to a lack of tonnage and a lack of knowledge/experience on my part.



Due to the crown of the fender near the front, i decided it would save time to make that as a separate panel from the rest of the top half of the fender. Both of the panels that make up the top half of the fender were made with an english wheel.



After some careful trimming for a tight, butt-welded seam, it starts coming together pretty quick.



I tried taking a picture this afternoon of the fender, but the sunlight creates too much of a glare for a good picture. I'll try to get a good picture when the sun sets this evening.

[p2architect]

That is way cool.
John D would be proud.

Later in his career he built that little all aluminum D car.

Later - I look forward to your ALL aluminum 63 2 door Lemans coupe.

Keep up the good work - it looks great already.

[Scott M]

John D's car was made of stainless steel, not aluminum.

Randy:

I'm the fat, bald guy carrying the '61 inner fenderwells who you met in the parking lot as you were leaving.

Nice work.

[Randy Ferguson]

Still not the greatest picture, but here's a finished shot.

[azkeebler]

Wow, that takes some serious time and skill. Very nice!! Please keep up the progress with other work!!

[70Steve]

Didn't expect to see this when I first read the title!!
Thanks for sharing Randy.Almost a crime to have to paint it.
Metal fabrication and coachbuilding has always intrigued me.
Look forward to updates.
Steve.

[mechanickeith]

MOST EXCELLENT!!!!!!!!!

What gage of aluminum & are you making inner bracing for the fender simular to the factory steel one??? Cant wait to see it all come together!!! I think the hood is going to be a lot more fun to make tho!!!!

[Randy Ferguson]

Hi Kieth,

I'm using .063 3003 H14. It's heavier gauge than the original parts, but much more resistant to dents. The inner structure will be just like the steel ones.

The hood shouldn't be too big of a deal. It's fairly simple. I bought 60"x144" sheets of aluminum for this project, so i can do the hood skin in one piece.

This is the type of panels I usually make.

[mechanickeith]

Hey Randy, Glad you went with a thicker sheet. The originals were so thin!! Cool that internal bracing will stay original. Best of luck with the hood!! That is an awfully big piece to shape!! Like I said, cant wait to see the finished product!!

Keith

PS:::::: That front end is just plain wicked!!! Not in my wildest wet dreams could I ever think of making that!!!

[Randy Ferguson]

Keith,

It's sort of like building a house....One piece at a time. The trick is to not try making larger panels than your skill level can handle. The more you do, the more confident you become. I used to make everything in smaller panels because I was afraid my skills were not up to handling larger pieces. If you fail on a larger piece, the cost to scrap it gets in your pocket pretty fast. I'm still learning new things everyday, but I'm not afraid to tackle large panels anymore.

Less than 10 years ago, I had no clue how to shape a piece of sheetmetal. If you want to learn it badly enough, you can. Never is a long time!!!!

[twooldgoats]

Originally Posted by Randy Ferguson

......Less than 10 years ago, I had no clue how to shape a piece of sheetmetal. If you want to learn it badly enough, you can.........

I agree with your philosophy 100%. The parts you're producing now are a tribute to an amazing amount of time and energy you must have put in to get this far. Thanks for sharing the pictures and the process.

Jim

[spartazoo]

Awesome! Thanks for sharing. Please keep posting updates.

Not sure if you noticed but I have the silver 63 Tempest test mule clone named "Born Too Late". A set of these would be right at home on my car.

Kip

[tom s]

Randy,great meeting you,glad I could help getting everyone together on this deal.Tom

[GUILTY,HO]

Are you going make and sell the fenders and hood ?
If so what kind of cost would they be.
I'm doing the 63 LeMans putting the 2006 running gear, floor pans, firewall, suspension and all in it, the aluminum fenders and hood would be nice.

[gregsgtos2]

i heard about 30k ?

[Randy Ferguson]

i heard about 30k ?

I'd do it for that.

I don't like to discuss prices on an open forum.

I would be happy to discuss pricing and availability with anyone interested though. Just send me a PM or an e-mail: [email protected]

[Keith Seymore]

Welcome, Randy - they look great.

K

[triathlonx13]

Nice to have options ! Nice work.

[Engine-Ear]

Very impressive!!

[fasteddy]

Randy, I am envious of your skill. I always wanted to learn metal work.